US10330404B2 - Heat exchanger component with embedded sensor - Google Patents
Heat exchanger component with embedded sensor Download PDFInfo
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- US10330404B2 US10330404B2 US15/381,809 US201615381809A US10330404B2 US 10330404 B2 US10330404 B2 US 10330404B2 US 201615381809 A US201615381809 A US 201615381809A US 10330404 B2 US10330404 B2 US 10330404B2
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- additively manufactured
- fiber channel
- tbc
- fiber
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1017—Multiple heating or additional steps
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- B22F3/1055—
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/112—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/16—Measuring arrangements characterised by the use of optical techniques for measuring the deformation in a solid, e.g. optical strain gauge
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K1/00—Details of thermometers not specially adapted for particular types of thermometer
- G01K1/14—Supports; Fastening devices; Arrangements for mounting thermometers in particular locations
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K11/00—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00
- G01K11/32—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using changes in transmittance, scattering or luminescence in optical fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/36—Electric or electronic devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/18—Heat-exchangers or parts thereof
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/18—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes sintered
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
-
- Y02P10/295—
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49982—Coating
Definitions
- the following description relates to heat exchangers and, more particularly, to heat exchanger components with embedded sensors that are assembled by way of additive manufacturing such as direct metal laser sintering (DMLS) or other three-dimensional (3D) printing methods.
- additive manufacturing such as direct metal laser sintering (DMLS) or other three-dimensional (3D) printing methods.
- determining temperatures inside gas turbine engines often require that special temperature sensors, which can survive in very high temperature and high pressure environments be used but those types of features can be expensive and often require that additional structural supports be built inside the devices.
- the specialized sensors and their associated structures can have poor reliability characteristics.
- an additively manufactured component includes an additively manufactured first part defining a first trench, an additively manufactured second part defining a second trench and a fiber optic sensor.
- the additively manufactured first and second parts are additively manufactured together with the first and second trenches corresponding in position such that the additively manufactured first and second parts form an assembled part with a fiber channel cooperatively defined by the first and second trenches.
- the fiber optic sensor includes a first sensor part embedded in the fiber channel and a second sensor part operably coupled to the first sensor part and extendible at an exterior of the assembled part.
- the additively manufactured first and second parts are formed from at least one of fused deposition modeling (FDM), fused filament fabrication (FFF), direct ink writing (DIW), stereo-lithography (SLA), digital light processing (DLP), powder bed and inkjet 3D printing (3DP), powder bed fusion (PBF), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), direct metal laser sintering (DMLS), laminated object manufacturing (LOM), directed energy deposition and electron beam freeform fabrication (EBF 3 ).
- FDM fused deposition modeling
- FFF fused filament fabrication
- DIW direct ink writing
- SLA stereo-lithography
- DLP digital light processing
- PPF powder bed and inkjet 3D printing
- PPF powder bed fusion
- EBM electron beam melting
- SLM selective laser melting
- SHS selective heat sintering
- SLS selective laser sintering
- DMLS direct metal laser sintering
- At least one of the additively manufactured first and second parts includes at least one of aluminum (Al), nickel (Ni), titanium (Ti), cobalt-based alloys, steels, ceramics, cermets, photopolymers and thermoplastics.
- a central axis of the fiber channel is offset from respective planes of outermost layers of the additively manufactured first and second parts.
- the fiber optic sensor is at least one of a strain sensor and a temperature sensor and further includes a processing unit to process sensor readings obtained by the first part.
- each of the additively manufactured first and second parts defines multiple first and second trenches, respectively, such that the assembled part has multiple fiber channels and the fiber optic sensor includes multiple first sensor parts respectively embedded in a corresponding one of the multiple fiber channels.
- the first sensor part includes a thermal barrier coating (TBC).
- TBC thermal barrier coating
- the first sensor part and the TBC tightly fit in the fiber channel.
- the first sensor part and the TBC are embedded with pre-loading in the fiber channel.
- the TBC includes a protruding surface feature and the fiber channel is defined by a corresponding one of the first and second trenches to include a recessed surface feature corresponding in position to the protruding surface feature.
- the fiber channel is defined by the first and second trenches to include first and second transverse channel components in which corresponding sections of the first sensor part and the TBC are respectively embedded.
- a fiber optic sensor for operable disposition in a fiber channel of an additively manufactured component.
- the fiber optic sensor includes a first sensor part embedded in the fiber channel and comprising an exterior surface and a thermal barrier coating (TBC) disposed thereon to protect the exterior surface during additive manufacturing processes, a second sensor part operably coupled at a first end thereof to the first sensor part and extendible at an exterior of the assembled part and a processing unit operably coupled to a second end of the second sensor part to process sensor readings obtained by the first part.
- TBC thermal barrier coating
- the first sensor part is configured for at least one of strain and temperature sensing.
- the TBC includes a protruding surface feature that corresponds with a recessed surface feature of the fiber channel.
- the first sensor part and the TBC each have corresponding sections that are respectively embedded in first and second transverse components of the fiber channel.
- a method of additively manufacturing a component includes additively manufacturing a first part to define a trench, laying down an optical fiber in the trench and additively manufacturing a second part onto the first surface and around the optical fiber to extend the trench into a fiber channel in which the optical fiber is embedded.
- the additive manufacturing of the first and second parts includes at least one of fused deposition modeling (FDM), fused filament fabrication (FFF), direct ink writing (DIW), stereo-lithography (SLA), digital light processing (DLP), powder bed and inkjet 3D printing (3DP), powder bed fusion (PBF), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), direct metal laser sintering (DMLS), laminated object manufacturing (LOM), directed energy deposition and electron beam freeform fabrication (EBF 3 ).
- FDM fused deposition modeling
- FFF fused filament fabrication
- DIW direct ink writing
- SLA stereo-lithography
- DLP digital light processing
- PPF powder bed and inkjet 3D printing
- PPF powder bed fusion
- EBM electron beam melting
- SLM selective laser melting
- SHS selective heat sintering
- SLS selective laser sintering
- DMLS direct metal laser sintering
- LOM
- the method further includes pre-loading optical fiber and the TBC in the fiber channel.
- the applying of the TBC includes forming a protruding surface feature and the additive manufacturing of the second part around the optical fiber includes forming a recessed surface feature corresponding in position to the protruding surface feature.
- the additive manufacturing of the first part includes forming the trench to include first and second transverse components
- the laying down of the optical fiber includes laying down sections of the optical fiber with the TBC applied thereto in the first and second transverse components
- the additively manufacturing of the second part includes extending the first and second transverse components of the trench into first and second transverse components of the fiber channel.
- FIG. 1 is a perspective view of an assembled part with an embedded fiber optic sensor in accordance with embodiments
- FIG. 2 is a side schematic view of the assembled part of FIG. 1 ;
- FIG. 3 is an enlarged schematic view of components of an additively manufactured first part of the assembled part of FIG. 1 ;
- FIG. 4 is an enlarged schematic view of components of an additively manufactured second part of the assembled part of FIG. 1 ;
- FIG. 5 is a diagram illustrating an additive manufacturing process for additively manufacturing a first part of the assembled part of FIG. 1 ;
- FIG. 6 is a diagram illustrating an additive manufacturing process for additively manufacturing a second part of the assembled part of FIG. 1 ;
- FIG. 7 is an enlarged schematic illustration of a fiber optic sensor positioned between additively manufactured first and second parts in accordance with embodiments
- FIG. 8 is an enlarged schematic illustration of preloading of a fiber optic sensor in accordance with embodiments.
- FIG. 9 is a top down view of protruding and recessed features to secure a fiber optic sensor within a fiber channel in accordance with embodiments.
- FIG. 10 is a top down view of a complex pathway of a fiber optic sensor within an assembled part in accordance with embodiments.
- additive manufacturing techniques are applied to allow for the integration of sensing elements into a structure or assembled part so that a self-aware component can be realized.
- Such components can monitor performance or conditions inside and outside of the self-aware component without the need to add on addition components that reduce reliability and increase cost.
- an additive build process is executed to provide a component with a shallow trench of about 75 microns in diameter in which an optical fiber can be placed.
- the additive build process proceeds and encases the optical fiber inside the resulting component.
- Optical leads are routed from the optical fiber to a transducer where sensor readings are converted to electrical signals as required for processing.
- a thin thermal coating can be provided on the optical fiber so that the optical fiber (melting point ⁇ 1700° C.) can withstand at least a few microseconds at a melt pool maximum temperature ( ⁇ 2900° C.) associated with certain additive manufacturing processes.
- Internal health monitoring can be performed to determine component temperatures or structural integrity issues for select locations with multiple leads/wires to thereby ensure robustness and to preclude reliability limitations.
- an additively manufactured component 10 is provided.
- the additively manufactured component 10 includes an additively manufactured first part 11 , an additively manufactured second part 12 and a fiber optic sensor 13 .
- the additively manufactured first part 11 includes a body 110 that is formed of multiple layers 111 and the additively manufactured second part 12 includes a body 120 that is formed of multiple layers 121 .
- the multiple layers 111 proximate to the upper surface 112 cooperatively define at least a segment of a first trench 113 with the uppermost one of the multiple layers 111 actually forming the upper surface 112 (see FIG. 3 ) and the multiple layers 121 proximate to the lower surface 122 cooperatively define at least a segment of a second trench 123 with the lowermost one of the multiple layers 121 actually forming the lower surface 122 (see FIG. 4 ).
- the additively manufactured first and second parts 11 and 12 are additively manufactured together. That is, the lower surface 122 of the additively manufactured second part 12 is additively manufactured onto the upper surface 112 of the additively manufactured first part 11 in the non-limiting and exemplary embodiment provided above.
- the additively manufactured first and second parts 11 and 12 thus form an assembled part 14 . Therefore, with the first and second trenches 113 and 123 corresponding with one another in terms of at least their respective positions, the first and second trenches 113 and 123 cooperatively define an optical fiber channel 15 .
- the fiber optic sensor 13 may be configured for sensing strain and/or temperature within the assembled part 14 and includes a first sensor part 130 , a second sensor part 131 and a processing unit 132 .
- the first sensor part 130 is embedded in the fiber channel 15 .
- the second sensor part 131 is operably coupled at a first end thereof to the first sensor part 130 and is extendible at an exterior of the assembled part 14 .
- the processing unit 132 is operably coupled to a second end of the second sensor part 131 and is configured to process and to analyze sensor readings obtained by the first sensor part 130 . In doing so, the processing unit 132 may be configured to consider heat transfer capabilities of the materials of the assembled part 14 .
- the processing unit 132 can be used to determine both the temperature of the interior of the assembled part 14 and to calculate temperatures of the peripheral portions of the assembled part 14 from the interior temperature.
- the additively manufactured first and second parts 11 and 12 may be fabricated by at least one or more of fused deposition modeling (FDM), fused filament fabrication (FFF), direct ink writing (DIW), stereo-lithography (SLA), digital light processing (DLP), powder bed and inkjet 3D printing (3DP), powder bed fusion (PBF), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), direct metal laser sintering (DMLS), laminated object manufacturing (LOM), directed energy deposition and electron beam freeform fabrication (EBF 3 ).
- FDM fused deposition modeling
- FFF fused filament fabrication
- DIW direct ink writing
- SLA stereo-lithography
- DLP digital light processing
- PPF powder bed and inkjet 3D printing
- PPF powder bed fusion
- EBM electron beam melting
- SLM selective laser melting
- SHS selective heat sintering
- SLS selective laser sintering
- DMLS direct metal laser
- the additively manufactured first and second parts 11 and 12 may be formed of at least one or more of aluminum (Al), nickel (Ni), titanium (Ti), cobalt-based alloys or any other type of metallic alloys, stainless or non-stainless steels, ceramics, cermet, photopolymers, powdered polymers and thermoplastics.
- the multiple layers 111 are laid down on a jig 20 in sequence with each of the multiple layers 111 being formed of metallic powder that is deposited and then melted and bonded to surrounding metallic materials by a laser that passes over the surface area of the deposited metallic powder.
- the laser avoids passing over the region where the first trench 113 is to be formed. This avoids the creation of metallic bonds and results in the definition of the segment of the first trench 113 once all of the multiple layers 111 are finally formed.
- each of the multiple layers 121 is formed of metallic powder that is deposited and then melted and bonded to surrounding metallic materials by the laser.
- the laser avoids passing over the region where the second trench 123 is to be formed so as to avoid the creation of metallic bonds in this region with the result being the definition of at least the segment of the second trench 123 once the multiple layers 121 are finally formed.
- a central axis of the fiber channel 15 can be aligned with or offset from respective planes of outermost layers (i.e., the upper surface 112 and the lower surface 122 ) of the additively manufactured first and second parts 11 and 12 .
- the fiber channel 15 has a circular cross-sectional shape, for example, the first trench 113 and the second trench 123 would each be formed to have semi-circular cross-sectional shapes of substantially similar size.
- the first trench 113 can be formed to have a segmented-circular shape that is larger or smaller than a semi-circle and the second trench 123 can be formed to have a complementarily segmented-circular shape that is smaller or larger than the semi-circle.
- each of the additively manufactured first and second parts 11 and 12 can be formed to define multiple first and second trenches 113 and 123 , respectively, such that the assembled part 14 has multiple fiber channels 15 .
- the fiber optic sensor 13 may include or be provided with multiple first sensor parts 130 that are each respectively embedded in a corresponding one of the multiple fiber channels 15 .
- additive manufacturing processes can generate extremely high local temperatures at locations where the laser light is incident on the deposited metallic powder.
- the additive manufacturing processing include DMLS and the deposited metallic powder includes aluminum (which has a melting temperature of about 660° C. and a boiling temperature of about 2519° C.) or nickel (which has a melting temperature of about 1455° C. and a boiling temperature of about 2913° C.)
- the local temperatures at which DMLS occurs can exceed the temperature range at which the fiber optic sensor 13 can be damaged. This is true even for high-purity, telecom-grade optical fibers whose melting point is around 1700° C. As such, as shown in FIG.
- At least the first sensor part 130 of the optical fiber sensor 13 may include an exterior surface 801 and a thermal barrier coating (TBC) 802 .
- TBC 802 is applied to the exterior surface 801 and thus disposed to protect the exterior surface 801 and the first sensor part 130 /optical fiber sensor 13 as a whole from thermal damage resulting from the DMLS processing.
- the first sensor part 130 and the TBC 802 are disposed to tightly fit in the fiber channel 15 . That is, where an interior surface of the TBC 802 conforms to a contour of the exterior surface 801 , an interior surface of the fiber channel 15 conforms to a contour of an exterior surface of the TBC 802 . As such, the first sensor part 130 can be securely held by frictional contact between abutting surfaces in the fiber channel 15 .
- the first sensor part 130 and the TBC 802 are embedded with pre-loading in the fiber channel 15 .
- This can be accomplished, for example, by laying down the first sensor part 130 and the TBC 802 in the first trench 112 and then applying localized pressure thereto (e.g., by pushing down on the TBC 802 with a probe) while the additively manufactured second part 12 is built up around them.
- the application of the localized pressure is relieved (e.g., by removing the probe) and the additively manufactured second part 12 is completed.
- the resulting preloading can increase frictional contact between abutting surfaces in the fiber channel 15 and can be accounted for by the processing unit 132 in analyzing sensor readings.
- the TBC 802 may include a protruding surface feature 901 and the fiber channel 15 may be defined by a corresponding one of the first and second trenches 113 and 123 to include a recessed surface feature 902 which corresponds in position to the protruding surface feature 901 .
- the protruding surface feature 901 can be a bump or a hook shaped element and the recessed surface feature 902 can be a dimple that is receptive of the bump or a reversed hook that engages with the hook shaped element. In either case, the protruding surface feature 901 and the recessed surface feature 902 mechanically interact with one another to secure the first sensor part 130 in place within the fiber channel 15 .
- the protruding surface feature 901 can be built up of the TBC 802 alone or may be formed as part of the first sensor part 130 . In the latter case, the TBC 802 is simply built up around and over the formation of the first sensor part 130 .
- the fiber channel 15 may be defined by the first and second trenches 113 and 123 (see FIG. 2 ) to include first and second transverse channel components 151 and 152 .
- first and second transverse channel components 151 and 152 corresponding sections 153 and 154 of the first sensor part 130 and the TBC 802 (if applicable) may be respectively embedded.
- multiple regions of the assembled part 14 can be accessible to the first sensor part 130 and the torturous path followed by the first sensor part 130 serves to secure the first sensor part 130 within the fiber channel 15 .
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Abstract
Description
Claims (13)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US15/381,809 US10330404B2 (en) | 2016-12-16 | 2016-12-16 | Heat exchanger component with embedded sensor |
EP17207805.7A EP3338919B1 (en) | 2016-12-16 | 2017-12-15 | Component with embedded sensor and process therefor |
US16/449,575 US11236957B2 (en) | 2016-12-16 | 2019-06-24 | Method of additively manufacturing a heat exchanger component with embedded sensor |
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US15/381,809 US10330404B2 (en) | 2016-12-16 | 2016-12-16 | Heat exchanger component with embedded sensor |
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US16/449,575 Division US11236957B2 (en) | 2016-12-16 | 2019-06-24 | Method of additively manufacturing a heat exchanger component with embedded sensor |
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US20180172369A1 US20180172369A1 (en) | 2018-06-21 |
US10330404B2 true US10330404B2 (en) | 2019-06-25 |
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US15/381,809 Active 2037-02-13 US10330404B2 (en) | 2016-12-16 | 2016-12-16 | Heat exchanger component with embedded sensor |
US16/449,575 Active 2037-09-26 US11236957B2 (en) | 2016-12-16 | 2019-06-24 | Method of additively manufacturing a heat exchanger component with embedded sensor |
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Cited By (1)
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US12011875B1 (en) | 2021-03-09 | 2024-06-18 | Resnent, Llc | Secondary object integration options for 3D electrophotography based additive manufacturing |
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EP3878630A1 (en) * | 2020-03-12 | 2021-09-15 | Nederlandse Organisatie voor toegepast- natuurwetenschappelijk Onderzoek TNO | Method of manufacturing an object and extrusion-based additive manufacturing system therefore |
US12062461B2 (en) * | 2021-02-04 | 2024-08-13 | Nuscale Power, Llc | Supports with integrated sensors for nuclear reactor steam generators, and associated systems and methods |
CN114850492B (en) * | 2021-12-13 | 2023-12-12 | 南京联空智能增材研究院有限公司 | Method for preparing component in-situ sensor based on additive manufacturing |
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Also Published As
Publication number | Publication date |
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US11236957B2 (en) | 2022-02-01 |
EP3338919A1 (en) | 2018-06-27 |
EP3338919B1 (en) | 2021-06-16 |
US20180172369A1 (en) | 2018-06-21 |
US20190331441A1 (en) | 2019-10-31 |
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